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Feb. 19, 192,9.

A. E. CLARKE INLAID LINOLEUM Filed Feb. 8, 1928 IHIIIIIIHWH lllllllllllllllllllll mms/TOR Aff/wf E. c/af/e wmdmx A TTORNE Y ljatented 19,

F ENT FFICE.

ARTHUR E. CLARKE, OF ARLINGTON, NEW JERSEY, .ASSIG'NOR TO CONGOLEUM-NAIRN, INC., A CORORATION OF NEW YORK.

NLAlD LNOLEUIVI.

Application filed February 8, 1928.

The present invention relates to floor coverings and to a process of manutacturing the same. More particularly does it relate to the manufacture of linoleum floor coverings havingan inlaid vari-colored pattern simulatine* hand-laid tiling.

Among` other objects my invention is intended to provide a novel, durable, and attract-ive inlaid linoleum havinga color pattern formed in relief, ane a novel and cliieient method of prooucingl the same.

The invention is particular nf applicable to the manufacture of inlaid linoleum simulating handdaid tiling, and will, therefore, be illustrated and described with particular reference to such embodiment, it being understood, however, that t-he invention is not so limited, but may also be embodied in other patterns.

In the drawing:

Figure. l is a plan view of a. piece of linoleum illustrating the successive steps in the process of its manufacture according,` to my invention.

Figure 2 is an enlarged section along the line llll of Figure l.

Figure 3 is an. enlarged sectional elevation of the completed floor covering.

Referring to the illustrated embodiment of the invention, numeral l indicates a suitable fabric base ma erial such as burlap or canvas, Upon the fabric base l, l apply a relatively thiol; layer of linoleum composition 2, which uniformly covers such base material. This layer serves not only as a foundation upon which the inlaid color pattern may he formed, but in itself constitutes a portion of such inlaid color pattern. 'lhe layer of linoleum composition may be formed and united with the burlap backing Tl in a sing-le operation, by means of sheeting or calcndering` rolls in the usual manner of making` mono-colored linoleum, or the. sheet of linoleum composition 2 may be formed separately and thereafter united, by pressure, with the backing'. The .linoleum composition layer 2' will usually be of a single colon which color will he chosen in a manner to simulate the mortar or other binder employed in hand-laid ceramic tiling'.

The uniform linoleum sheet thus formed, may be partly cured or seasoned to increase its stability and toughness for the subsequent perations. However, if employed this preliminar seasoning should not be carried he- Scrial N0. 252,704.

vond the point at which the linoleum will flow to a limited extent under the iinal consolidatine` pressure and at which the super'- imposed inlays of unseasoned linoleum composition will thoroughly bond therewith. ln some cases, the partial seasoning` may be dis pensed with entirely and the freshly formed linoleum sheet employed directly in the subsequent operations. Y

Upon the uniform unseasoned or partially seasoned linoleum sheet thus produced, I form the desired inlaid color pattern. Accordiup, to my invention, I arrange upon the foumilation layer a plurality of blocks or tesserze 3, 4l, simulating flooring tile, such blocks or tesser preferably being` cnt or stamped from preformed unseasoned sheets of linoleum composition which are preferably, though not necessarily, of a thickness substantially less than that of the linoleum composition layer 2. As distinguished from the ordinary type of block inlaid linoleuin, however, the tessertc 3, l are positioned in non-contiguous relation providing narrow channels therebetween, whereby strips or portions 5 of the composition layer 2 are left visible in the completed color pattern to simulate the mortar joints between the tiles. The inlaying;1 process may be carried out by hand, if desired, although my invention facilitates the application of the automatic rotary inlaying machines of the falten type in the proouction of pattern linoleum of the type described.

The block inlays or tesserze 3, ll, simulating tile, are preferably, as indicated in the drawing, of varyingcolors or of different shades of the same color. For simplicity in illustration, l have shown inlays of two colors, although the number of different colors which may be utilized, is obviously not so limited. Furthermore, the inlays of varying colors may be arranged in a regular manner as shown, or with an irregularity of occurrenel-x simulating the irregular patterns of handlaid tiling, such arrangement being,- a matter of design.

The inlaid linoleum formed in the manner above set forth, is subjected to heavy pressure to unite the unseasoned blocks or tesserte 3, 4 with the layer of unseasoned or partially seasoned composition 2, to form a single integral mass. Simultaneously with the consolidation, the edges 7 of the blocks or tes? serge 3, et under the pressure beine` exerted, lloiv laterally to ay liniited extent and the exposed portions et the hase layer tion' ni Ward, thereby causing such blocks to he iinpressed into the surface et the 'toundatien layer and the Whole to assuiiie the orin shape shown in Figure 3. In this manner, by suitably `governing,` the pressure, the hloelrs and foundation layer are disposed at different suri'aee levels, and at the saine tinie the variation in surface levels between the raised an d recessed portions ot the inlaid linoleuni is tornied with a smooth. conter r as shown at 8, 'thereby preventing' the retention ot dirt and allowing' the surtace to he easily cleaned. may

wherein the inlaid linoleuin is p tween a smooth-surface roll eng'ijn tace of the goods and e, heavy resilient blanket supported by a plurali v of Cinall- Idiameter smooth-surface re 1ere t 'he inlays 3, 4, are of considerable th irltness, lion'- ever, it may heconie desirable to eiiect the consolidation with a suitably ribhed roll or plate wliereon the ribs or raised portions coincide with the channels or portions et the completed color pattern. According to this latter prac-tice, the ribs or raised portions o't the consolidated roll or plate do not serve to indent or einhoss, ut simply to torni a ufall of smooth contour against which the inlays 3, 4 may flow under the consolidating pressure exerted, thereo5T asearingv that the contour ot the recessed portions in the completed product will he ot the desired contiguration. The consolidated product then seasoned or cured by heat, according to well-l noivn practice.

My invention provides a novel and eilicient niethod tor the iiiaiiiirtactuie oit varieolored inlaid linoleuin hy the .iloelr inlaf,7 or straightline process, Whieh inethod avoids the major disadvantage oit such products as heretofore known, that is, the suseeptihi to breaking; ot the juncture et the inl Y Thus, by constructing the covering ivi` a unitary and unitori'n layer ot linoleuni .en position 2 ot substantial thickness i? portion. of the color pattern and Serin foundation 'tor the reniaiiiinfr portion ot suc color pattern, I obtain a pro et Tvhicli is for threugrliout sulisnntially unitorin strength and which Will not tend to bre split along the juncture ot the vari-colo ed inlays. IVhile I have illustrated the invention applied to the manufacture of tile patterns, it may likewise be applied to the nianui'actn e of other linoleurn patterns as desired, ard. do not Wish to liinit the scope s ich in tion except as defined in the 'tollerA l, The method oi ina-king liner tiny; which comprises forming' a .ndatioi layer of linoleuni composition oi iq-endet product; forming separate in- .r linoleuni composition, each siniulat tile; )regering the ouneation layer a'- inlays to present plastic surface-portions c` tile oit being Welder,L together and iiitelgrated under pressure, and of permitting the inlays to be impressed into 'the suriaee of the ioundation layer tace-portions oi' the under pressure aspri aantially non-conti` imitation oi" the arrange upon the p astio suriace ot ayer,

so that areas ot the la between inlajs 'to 'ess twine' appljfiiie pi ure s tie inla., c the suriace of the on layer, and to iveld and integr tivo, and to reuse part or the spaces hetrfeeiinla ytion laver to lionv vsg and governing;` 'i e the relative iin- .v nys and flowing ot the i id to dispose the areas oi itiveen inlays at a lower 1 ot the inlays, While th the inlays collecti -ely a l pressi it oundttion i' eveL preserving bene Ytounuatieni l y si geneous stratum of' 'the toundation 'erial throughout the lietantially co itinuous, integral, and lioinolayer inaougli, duran e, in

independeiitlyv of Y YWeen tue in lays and the foundation 2. The inet-lied if inalii eoniprises termino ar i'oun in linoleunfi Composition ot suis' nt ness and homogeneity ei: -ng ouslv throughout the area tue intended product and having' surtaee-nor- .Y .5 i i tions capable perni' ys to 'se iin- IVaree-sed into the sur rounilation ,inev snrtaeaportions r pres -valli' non layer and oi perni' A,

ratte' to tion' soinewlia" inbline; inlays in subsi relationships upon itoniidatior lover i c o, tire clirougliout the intended area or lili) llt) Cil

whereby said stratum supplies a tough, durable, integral body for the product, independently of the inlays.

3. The method of making` linoleum which comprises forming a foundation layer of linoleinn composition; formingY separate inlays of linoleum eon'iposition; preparing the foundation layer and inlays to present plastic surface-portions capable of being welded together and integrated under ixn'essure, and of permitting' the inlays to be impressed into the Surface of the foundation layer, and of permitting surfaccsportions of the latter to flow somewhat under press rc; assembling;l inlays in substantially non-contiguous relationships upon Vthe plastic surface of the foundation layer, 'that areas of the latter remain exposed between inlays; applying pressure to impress the inlays into the surface of the foundation layer, and to weld and integrate the two, and to cause part of the foundation layer to flow into spaces between inlay; and governing' the pressure to predetermine the relative impressine` of the inlays and flowingl of the foundation layer, and to' dispose tho areas of the foundation layer between inlays at a loweil surface level than that of the inlays.

4;. The method of making` linoleum which comprises forming' a foundation of linoleum composition of substantial thickness having plastic surface-portions permitting inlays to be impressed into the foundation; assembling;l inlays in substantially non-contiguous relationships, upon the plastic surface-portions of the foundation; applyingv pressure to im press the inlays into the foundation and to produce different surface levels of thc inlays and such portions of the foundation layer as intervene between inlays, while preserving beneath the inlays collectively a substantially thick stratum of the foundation material which supplies a strongl body for the product independenly of the inlays.

The method oi makin;Y linoleum which comprises forming' a foundation layer of linoleum composition of substantial thickno and formingl inlays; the foundation layer and inlays having surfacewportions capable of beingl welded together and intergraied under pressure.. and of permitting the inlays, to he impro ed into the surface ofthe '.'oiuulution layerA` and permitting surfaceporiions of the latter to flow somewhat under L sure; assembling` inlays in substantially non-rontiguous relationshipel upon the plastic surface of the foundation layer so that areas of the latter remain exposed between inlays; applyii' pressure to predetermine the relative impressingy of the inlays and flowing` of the foundation layer, and to dispose at different surface levels the inlays and the areas of foundation layer between inlays, while preserving' beneath the inlays collectively a stratum of the foundation layer material which supplies a substantially integral body for the product independently of the inlays.

The method of making linoleum which eoniprises forming a foundation layer of linoleum composition; forming sepa ate inlays of linoleum composition; the foundation layer and inlays being plastic and capable of being molded and welded together and inte- `grated under pr issure, and of permitting the inlays to be impressed into the surface of the fouiulation layer; assembling; inlays in substantially non-contiguous relationships upon the surface of the foundation layer, so that areas of the latter remain exposed between inlays; impressing the inlays into the surface of the foundation layer, and welding and integrating the two; and disposing at dif ferent surface levels the inlays and the areas of foundation layer between inlays; and moldingprojecting portions of the resulting product to avoid abrupt corners on its surface.

7. s a new article of manufacture, a linoleum eomprisimc)` a foundation layer of linoleum composition of substantial thickness and homogeneity extending continuously throughout the area of the linoleum; separate inlays of linoleinn composition embedded at least partially in the surface of Said foundation layer, and welded and integrated therewith, said inlays being positioned in substantially non-contiguous relationship so that portions of the foundation layer are interposed and exposed between the inlays; the inlays and areas of the foundation layer between inlays beine; disposed at different surface levels; and the foundation layer having a continuous homogeneous stratum extending integrally beneath the inlays collectively supplying' a strong body for the linoleum independently of the bonds between the inlays and the foundation layer.

S. As a new article of manufacture, a linoleum comprising a foundation layer of linoleum composition; inlays embedded at least partially in the surface of said foundation layer, positioned in substantially non-contiguous relationship so that portions of the foundation layer are interposed and exposed between the inlays; the inlays and areas of the foundation layer between inlays being disposed at different surface levels; and the foundation layer having a substantially thick stratum extending); beneath the inlays collectively supplying` a strong body for the ln'oduet.

9. As a new article of manufacture, a linoleuin comprising a foundation layer of linoleum composition separate inlays of linoleum eonuiosition embedded at least partially in the surface of said foundation layer,` and welded and integrated therewith, said inlays being' positioned in substantially non-contiguous relationship, so that portions of the foundation layer are interposed and exposed lietween inlays; lie inlays and zii'oee of the foundation layeiq between inlays being' disposed at different eeifsice levels; and tlie :foundation lejfei' having; :i etmum extending siilielzmtially integrally beneath tile inlays.

l0. As a new rliole of iiieiiu'feoliiie, a liiioleluii cempi'ieing :i foundetioii leyei of linoleum @om 3ssl-ion g sequel-bale inlays of linoleum eeiiipeei'tioii embedded L leest pziiflizilly in the Surface of seid femm i ion layer7 eiid Welded and integrated llieievrilili llie im being; in srubslzuiielly neil-contiguous releioneliip oii die 'foundation layer, so the-t poi"- lione1 el? llie lai-iler are interposed and exposed liewoen inlays; the inlays and the areas of' loiiiideion layer between iiilziys being loceled ziidii' eieiit surface levels; end the pi'ojeoliif; poi-lione of lie surface of the piod'aio' being devoid of elemplcomers.

lo ioiiy whereof, l efix my Signature.

ARTHUJR E. CLARKE. 

